Piston ring

Abstract

A piston ring for at least one of a piston of an internal combustion engine and a compressor may include at least one substantially annular metallic base having a nitrided layer. The base may include at least one chamfer and at least one outer surface that maintains contact with a layer of lubricating oil. The nitrided layer may exhibit a substantially constant thickness over at least one surface of the base and the at least one chamfer. The nitrided layer may include a nitrided diffusion layer that maintains direct contact with the layer of lubricating oil and has a residual tension ranging from +100 megapascal to 100 megapascal.

Claims

1. A piston ring for at least one of piston of an internal combustion engine and a compressor, the piston ring comprising: at least one substantially annular metallic base having a nitrided layer, the base including at least one chamfer and at least one outer surface, the at least one outer surface being configured to maintain contact with a layer of lubricating oil; wherein: the nitrided layer is applied on the at least one chamfer and the at least one outer surface after the at least one chamfer is formed; the nitrided layer has a substantially constant thickness over at least one surface of the base and the at least one chamfer; the nitrided layer consists of a single nitrided diffusion layer that has a residual stress ranging from +100 megapascal to 100 megapascal; and the at least one outer surface, includes a hard ceramic film applied directly on the single nitrided diffusion layer for providing good adhesion therebetween, and the hard ceramic film is applied without any machining of the nitirded layer due to there never having been a nitrdided white layer formed on the piston ring.

2. The piston ring according to claim 1, wherein the hard ceramic film is generated via at least one of physical vapor deposition (PVD) and chemical vapor deposition (CVD).

3. The piston ring according to claim 1, wherein the annular metallic base includes at least one of stainless steel, martensitic stainless steel, iron, or cast iron.

4. The piston ring according to claim 1, wherein the annular metallic base includes a fatigue resistance greater than 800 megapascal (MPa).

5. The method according to claim 1, wherein the single nitrided diffusion layer has a thickness of 20 to 150 micrometers.

6. A method of manufacturing a piston ring, comprising: providing a substantially annular metallic base having a peripheral outer surface, a peripheral inner surface, an upper surface, and a lower surface; forming at least one chamfer in the annular metallic base; nitriding at least one of the surfaces and the at least one chamfer of the annular metallic base so as to define a single nitrided. layer on the at least one of the surfaces and the at least one chamfer after the at least one chamfer is formed, the single nitrided layer consisting of a single nitrided diffusion layer having a substantially constant thickness and a residual stress ranging from +100 megapascal to 100 megapascal; and applying a hard ceramic film directly on the single nitrided diffusion layer for providing good adhesion therebetween, and the hard ceramic film being applied without machining of the single nitirded layer prior to applying the hard ceramic film, due to there having never been a nitrided white layer formed on the piston ring.

7. The method according to claim 6, wherein the chamfer is formed via machining.

8. The method according to claim 6, further comprising generating the hard ceramic film via at least one of physical vapor deposition (PVD) and chemical vapor deposition (CVD).

9. The method according to claim 6, wherein the annular metallic base includes at least one of iron, cast iron, steel, stainless steel, or martensitic stainless steel.

10. The method according to claim 6, wherein the single nitrided diffusion layer is present on each surface of the annular metallic base.

11. The method according to claim 6, wherein the single nitrided diffusion layer has a thickness of 20 to 150 micrometers.

12. The method according to claim 11, wherein the hard ceramic film is generated via at least one of physical vapor deposition (PVD) and chemical vapor deposition (CVD).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present will now be described in greater detail with reference to an example of embodiment represented in the drawings. The figures show:

(2) FIG. 1 is a photograph of a piston ring showing the origin of a crack that has led to break of the ring;

(3) FIG. 2 shows the actuation of the concentration of tensions on a region of an edge of the piston ring;

(4) FIG. 3 shows a piston ring of the of the present invention;

(5) FIG. 4 shows a piston ring of the present invention; and

(6) FIG. 5 shows another piston ring of the present invention.

DETAILED DESCRIPTION

(7) The present invention refers to a piston ring, particularly for use in the groove of a piston of an internal combustion engine, and such a ring may be applied both as compression ring and as oil-scraping ring.

(8) As described above, in order for a piston ring to maintain its performance during millions of cycles, the metallic base 10 by which it is formed needs to receive an adequate surface treatment.

(9) In the case of the present invention, the piston ring will receive at least one special nitriding treatment. In this regard, it should be noted that the metallic base 10 of the piston ring compatible with such a treatment should be composed mainly by iron, and one may use cast iron, steel, stainless steel, martensitic stainless steel, or any other alloy that proves to be compatible.

(10) The main characteristics of the piston ring of the present invention are due to that fact that it is subjected to surface treatment only in its final form. In other words, the ring will be subjected to the special nitriding treatment after being provided with the chamfers 15 in its final dimension, and does not require any machining process after the special nitriding treatment.

(11) Such a characteristic brings per se an advantage over the prior art, since the component is not subjected to additional internal tensions resulting from machining On the other hand, the size of the chamfers 15 may be larger, so as to prevent live edges at the ring corners, which, as shown in FIG. 2, enables one to prevent high concentrations of tensions.

(12) The sum of the combination provided by the possibility of using larger chamfers 15 with the fact that the component is not subjected to a machining process enables one to reduce significantly the compressive tensions of the component after nitriding.

(13) In order to achieve such a result, a piston ring comprising a substantially annular metallic base 10 is provided with at least one outer surface 11, 12, 13, 14, which will maintain contact with a layer of lubricating oil, such as a peripheral outer surface, a peripheral inner surface, an upper surface and a lower surface. It should be noted that the outer surface 11, 12, 13, 14 comprises or does not comprise a chamfer 15 that is in its final dimension (see FIGS. 3 and 4).

(14) Taking a piston ring with the above-described geometry, one subjects the metallic base 10 to a special nitriding layer. Such a nitriding layer consists only of the two nitriding layers usually applied by the prior art. Thus, the outer surface of the base 10 receives a nitrided layer consisting of only the diffusion layer 5, without deposition of the white layer that is typically deposited onto the rings of the prior art. It should be noted that, in order to achieve the results of the present invention, the thickness of the nitrided diffusion layer 5 should range from 20 to 150 micrometers. It should be noted that the nitrided diffusion layer 5 will be directly in contact with the external environment, that is, it will maintain contact with the film of lubricating oil of the internal combustion engine or compressor.

(15) As already said, the white layer is very hard, fragile and porous, and so, in the case of the rings of the prior art, it has to be removed for subsequent deposition of a hard ceramic film whatever. In the case of the present invention, the metallic base is exclusively provided with a nitrided diffusion layer 5, without the need to remove it if one wishes to deposit a hard ceramic film subsequently.

(16) Thus, after deposition of the nitrided diffusion layer 5, one may then deposit directly onto one of the outer surfaces 11, 12, 13, 14 a hard ceramic film 16 generated by physical vapor deposition (PVD) or by chemical vapor deposition (CVD) with a view to improve the mechanical properties. See FIG. 5.

(17) In other words, the nitrided diffusion layer 5 is capable of receiving a hard ceramic film 16, guaranteeing good adhesion between the two coating. The existence of a white layer prevent adhesion difficulties, as well as the high compression tensions resulting from conventional nitriding, thus imparting to the piston ring of the present invention a number of benefits in its mechanical properties.

(18) Table 2 presents a number of bench tests with a view to demonstrate the advantages resulting from the present invention with respect to residual tension. The samples were tested to evaluate the residual tension at the outer lower chamfer 15 of the rings of the present invention (Exp. 3) with respect to the rings of the prior art after nitriding (Exp. 1) and after machining the chamber 15 (Exp. 2).

(19) TABLE-US-00002 TABLE 2 Comparison of the residual tension between the rings of the present invention and that of the prior art Residual tension at the outer lower chamfer (MPa) Prior art Present After invention After machining After nitriding the chamfer nitriding Samples Exp. 1 Ex. 2 Exp. 3 1 149 344 21 2 203 511 31 3 200 504 26 4 219 487 8 5 277 485 19 Average 230 466 21

(20) As can be seen, the present invention exhibits residual tension values 90% lower than that found in the rings of the prior art, only because the nitriding takes place on the ring already provided with chamfers. Such results impart absolutely desirable mechanical properties for the application for which they are intended. Thus, it is evident that non-formation of the white layer is fundamental to the success of the present invention.

(21) By nitriding the ring surfaces with only the diffusion layer, there is no need to carry out the machining step, and so the residual tension data after machining surprise with an average value 22 times lower. Indeed, a ring of the present invention may exhibit residual tension values ranging from a positive value of 100 Mpa to a negative value of 100 Mpa (+100 to 100 Mpa), which is absolutely desirable.

(22) The present invention can invariably achieve better results when compared with the rings of the prior art. In order to corroborate this, one should observe the results presented in Table 3.

(23) TABLE-US-00003 TABLE 3 Bench tests carried out with two million cycles on rings of the prior art and of the present invention. Bench fatigue test (calculation of the tension after 2 million cycles without failure) Prior art 700 MPa fatigue resistance Present invention 900 MPa fatigue resistance

(24) The above table referring to mechanical fatigue shows that the rings subjected to the special nitriding treatment of the present invention provide an improvement when compared with the rings of the prior art.

(25) One should observe that the piston rings of the present invention have achieved an improvement of 30% in the fatigue limit as compared with conventional rings. The rings of the present invention have borne two million cycles under a tension of 900 Mpa, and the rings of the prior art bore the same number of cycles, but at a maximum tension of 700 Mpa. It should be noted that at a tension higher than 700 Mpa the rings of the prior art broke before reaching two million cycles.

(26) In short, the present invention can prevent the drawbacks of the prior art as far as the lack of adhesion of a hard film is concerned, enabling it to be deposited directly in contact with the nitrided diffusion layer 5. On the other hand, the nitriding carried out by the prior art provides improvements in the level of the process, since it enables one to make larger chamfers 15 prior to nitriding, without the need for subsequent machining In addition to ease at production level, the piston ring of the present invention achieves mechanical properties that are markedly superior to those of the prior art, enabling the application of the rings of the present invention under severer conditions.

(27) A preferred example of embodiment having been described, one should understand that the scope of the present invention embraces other possible variations, being limited only by the contents of the accompanying claims, which include the possible equivalents.